Body, Front: Lock Carrier With Attachments, Removing and Installing

Body, front
Page 1 of 19
50-1
Body, front
Lock carrier with attachments, removing
and installing
1 - Hex bolt (6x)
45 Nm (33 ft lb)
2 - Hex bolt
45 Nm (33 ft lb)
3 - Hex bolt (4x)
10 Nm (7 ft lb)
4 - Hex bolts (2x)
10 Nm (7 ft lb)
5 - Access hole for special tool
For service position, attach special tool
3369 here
6 - Cowl attachment hole
Attachment for service position
http://127.0.0.1:8080/audi/servlet/Display?action=Goto&type=repair&id=AUDI.B5.BD01.50.1
11/20/2002
Body, front
Page 2 of 19
50-2
7 - Lock carrier
Removing:
- Remove bumper
page 63-1 .
- Remove noise insulation panel

50-18 .
- Disconnect hood lock cable
10 .
page
page 55-
- Drain engine coolant and disconnect

coolant hoses
Fig. 2 .
- Disconnect condenser from lock carrier
only (do not disconnect any lines) and
secure with wire (e.g. at front wheel).
Repair Manual, Heating & Air Conditioning,
Repair Group 87
Notes:
Do not suspend condenser by its lines.
Condenser lines must not be bent or
kinked under any circumstances.
- Remove hydraulic oil cooler only (do not
disconnect lines)
Fig. 1 .
Repair Manual, Suspension, Wheels, Steering,
Repair Group 48
11/20/2002
Body, front
Page 3 of 19
50-3
Notes:
Do not suspend hydraulic fluid cooler by its
lines.
Hydraulic fluid cooler must not be bent or kinked
under any circumstances
On vehicles with automatic transmission,
remove ATF cooler
Repair Manual, Automatic Transmission, Repair
Group 37
On vehicles with charge air cooler, remove
intake air duct
- Loosen seal for hood -8- at left and right
where fender meets lock carrier -7-.
- Remove bolts -3- and -4-.
A second mechanic is needed to support
lock carrier -7- Remove bolts -1- and -2-.
11/20/2002
Body, front
Page 4 of 19
50-4
Installing:
- Install in reverse order of removal.
- Adjust headlights.
Adjusting:
- Center lock carrier -7- between fenders.
- If fenders and hood are also being
replaced, center them in relation to one
another before adjusting lock carrier.
8 - Hood seal
9 - Hood lock cable
Disconnecting
page 55-10
10 - Hole in side panel
11/20/2002
Body, front
Page 5 of 19
50-5
Fig. 1
Disconnecting hydraulic fluid cooler
- Remove screws for cooling line (for power steering) at engine support
and transmission.
Fig. 2
Disconnecting coolant hose
- Drain coolant from radiator.

- Pull out locking element for coolant line connecting flange at bottom of
radiator and remove connecting flange.
- Bleed coolant system.
Repair Manual, General, Engine, Repair Group 19
11/20/2002
Body, front
Page 6 of 19
50-6
Fig. 3
Disconnect hose for charge air cooler
- On vehicles with charge air cooler, loosen bolt on hose clamp (arrow).
- Remove hose.
- Unscrew air duct to air cleaner at cowl and lift out.
- Disconnect harness connectors for headlights, headlight height

adjustment and blinkers.
- Disconnect harness connector for coolant system temperature sensor
for coolant fan at lower coolant hose area at radiator (left).
11/20/2002
Body, front
Page 7 of 19
50-7
Lock carrier service position

Notes:
Do not remove noise insulation. Loosen only
front quick-release screws page 50-18 .
Bumper removed
1 - Combination bolt
45 Nm (33 ft lb)
45 Nm (33 ft lb)
10 Nm (7 ft lb)
10 Nm (7 ft lb)
5 - Access hole for special tool
For service position, attach special tool
3369 here
6 - Cowl attachment hole
Attachment for service position
11/20/2002
Body, front
Page 8 of 19
50-8
7 - Lock carrier
For service position
- Screw special tool 3369 into threaded
bore -5- on left side Fig. 1
- Remove left and right mounting screws 1-.
- Remove mounting bolts -3- and -4- and
pull lock carrier -7- forward.
- Secure lock carrier
Fig. 2 .
8 - Hood seal
9 - Hood lock cable
10 - Hole in side panel
Note:
After assembly of the lock carrier, check headlight
positioning and adjust if necessary.
11/20/2002
Body, front
Page 9 of 19
50-9
Fig. 1
Screw in special tool 3369
- Screw special tool 3369 in at left and right as shown.

- Pull lock carrier forward until rear hole in lock carrier aligns with front
threaded hole in fender flange.
Fig. 2
Secure lock carrier
- Secure lock carrier with screws at left and right as shown.
11/20/2002
Body, front
Page 10 of 19
50-10
Front fender ( VIN 8D XA 200 000),

assembly overview
4.5 Nm (40 in. lb)
2 - Threaded rivet
Threaded rivet is inserted using VAG1618A
3 - Combination bolts (2x)
7.5 Nm (66 in. lb)
4 - Phillips head screw
4.5 Nm (40 in. lb)
5 - Metal nut (2x)
6 - Fender
Remove bumper
page 63-1 .
Remove wheelhousing liner

31 .
Remove end plate
page 66-
Fig. 1 .
Remove headlights Repair Manual,

Electrical Equipment
Disconnect electrical connectors for side
blinkers
- Remove bolts -1-, -3-, -4-, -7-, and -11-.
11/20/2002
Body, front
Page 11 of 19
50-11
7.5 Nm (66 in. lb)
8 - Bracket
7.5 Nm (66 in. lb)
10 - Metal nut
7.5 Nm (66 in. lb)
11/20/2002
Body, front
Page 12 of 19
50-12
Fig. 1
Removing and installing end plate
- Remove front wheel.

- Remove wheelhousing liner
page 66-31 .
- Remove bolt -2- (2x).

Tightening torque: 2.5 Nm (22 in. lb)
- Remove endplate -3- from fender -4-.
1 - Expanding clip (2x)
11/20/2002
Body, front
Page 13 of 19
50-13
Front fender (VIN 8D XA 200 001

S4), assembly overview
and
4.5 Nm
2 - Threaded rivet
The threaded rivet is inserted with VAG
1618 A.
3 - Combination bolts (2x)
7.5 Nm
4 - Phillips-head screw
4.5 Nm
5 - Phillips-head screw
Only installed for S4.
4.5 Nm
11/20/2002
Body, front
Page 14 of 19
50-14
6 - Snap-on nut
Only installed for S4.
7 - Fender
Drill additional hole at bottom for S4 fender
Fig. 2 .
Removing:
- Remove bumper
page 63-5 .

31 .
page 66-
- Remove headlights
Repair Manual, Electrical Equipment, Repair
Group 94, headlights, headlights, removing and
installing.
- Disconnect harness connector for side
turn-signal.
- Remove end plate
Fig. 1 .
- Remove bolts -1-; -3-; -4- (bolt -5- only

for S4) -8-; -9- and -14-.
11/20/2002
Body, front
Page 15 of 19
50-15
8 - Metal bolt
7.5 Nm
9 - Metal bolt
7.5 Nm
10 - Bracket
11 - Metal bolt
7.5 Nm
12 - Metal bolt
7.5 Nm
13 - Bracket
10 Nm
7.5 Nm
11/20/2002
Body, front
Page 16 of 19
50-16
Fig. 1
Removing and installing end plate
- Remove front wheel.

page 66-31 .
- Remove bolt -2- (2x).

Tightening torque: 2.5 Nm
- Remove end plate -3- from fender -4-.
- Expanding clip -1- (2x).
11/20/2002
Body, front
Page 17 of 19
50-17
Fig. 2
Drilling hole for S4 fender
Note:
For part replacement, drill hole before painting.
- Drill 7 mm diameter hole in fender. Dimension -a- = 22mm and -b- =
8mm.
- Restore corrosion protection at edges of hole.
Fig. 3
Lower fender mount (S4)
- Slide speed nuts -4- onto door sill from bottom.

- Speed nuts -5- only for S4
- Secure fender -1- at bottom using reinforcing bracket -2- and bolts -3-.
11/20/2002
Body, front
Page 18 of 19
50-18
Noise insulation panel, assembly overview

1 - Quick-release screw
Remove only this quick release screw for
service position
Three pieces
2 Nm (18 in. lb)
2 - Front noise insulation
3 - Quick release screw
Three pieces
If rear noise insulation panel is also - 4 being installed, then longer quick-release
screws must be used
2 Nm (18 in. lb)
4 - Rear noise insulation panel
Only installed for certain engine types
Installed over noise insulation panel -25 - Quick-release screw
Two pieces
2 Nm (18 in. lb)
11/20/2002
Body, front
Page 19 of 19
50-19
6 - Mounting for noise insulation panel

Position -9- must face left side of vehicle
7 - Bolt
Two pieces
7.5 Nm (66 in. lb)
8 - Plate nut
Two pieces
9 - Plate nut
Three pieces
10 - Clamping pin
Two pieces
11 - Wheelhousing liner
12 - Bumper
13 - Lock carrier with attachments
11/20/2002

Body, Front: Lock Carrier With Attachments, Removing and Installing

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Body, Front: Lock Carrier With Attachments, Removing and Installing

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Body, front

- Remove noise insulation panel

- Drain engine coolant and disconnect

10 - Hole in side panel

Disconnecting hydraulic fluid cooler

Disconnecting coolant hose

- Drain coolant from radiator.

Disconnect hose for charge air cooler

- Disconnect harness connectors for headlights, headlight height

Lock carrier service position

Screw in special tool 3369

- Screw special tool 3369 in at left and right as shown.

Secure lock carrier

- Secure lock carrier with screws at left and right as shown.

Front fender ( VIN 8D XA 200 000),

Remove wheelhousing liner

Remove headlights Repair Manual,

Removing and installing end plate

- Remove front wheel.

- Remove bolt -2- (2x).

Front fender (VIN 8D XA 200 001

- Remove wheelhousing liner

- Remove bolts -1-; -3-; -4- (bolt -5- only

Removing and installing end plate

- Remove front wheel.

- Remove bolt -2- (2x).

Drilling hole for S4 fender

Lower fender mount (S4)

- Slide speed nuts -4- onto door sill from bottom.

Noise insulation panel, assembly overview

6 - Mounting for noise insulation panel

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